Jdub goes there 1981 650e rebuild

[jdub6092]

You should remove the cylinder barrel. The base gasket needs replacing, OEM gaskets ONLY. And you may want to replace the rings too. Yes, more money, but it's worth the expense in the long run.

I will eventually replace the base gasket for sure. Will I need a special tool for removing the pistons from the rods? Or is there a homebrew method.

I see you are from Torrance. I lived off of Crenshaw just up the hill in PV Peninsula. I bought the bike at Laguna Hills Suzuki. Don't think they are still in business.

[jdub6092]

Frame2.jpg
Frame degreased and washed. Have not decided on whether to send out for sandblasting and powder coat or sand it down partially and repaint myself.
I have some aircraft stripper standing by as well.
Any suggestions? Best bang for buck?

[Nessism]

You should remove the cylinder barrel. The base gasket needs replacing, OEM gaskets ONLY. And you may want to replace the rings too. Yes, more money, but it's worth the expense in the long run.

[jdub6092]

Dirty engine3.jpg
Looks pretty filthy, but I actually only spent about 20 minutes on #4 piston using carb cleaner and a nylon then wire brush.
Could probably save time pulling the cylinder head and soaking the pistons in chem-dip or dropping them in the ultrasonic cleaner.

[jdub6092]

After seeing my same model restored by kiwi canuck, I decided to do a full restoration on my 1981 gs650e.
I have been doing little bits here and there. Cleaning, sanding, polishing, a little bit of painting, replacing the rear tire and bit by bit, tearing down the frame.
I eventually had to face the most intimidating task for me - removing and tearing down the engine.
Other than 4 broken valve cover bolts, it hasn't been too bad. I've watched many hours of youtube, and looked at this forum enough to build my confidence that I can indeed do this.

Pictures coming.